Bed spring machine



C. H. GAIL June 2, 1959 BED SPRING MACHINE 3 Sheets-Sheet 1 Filed Jan. 5, 1955 INVENTOR.

ATTORNEY C. H. GAIL June 2, 1959 BED SPRING MACHINE 3 Sheets-Sheet 2 Filed Jan. 3, 1955 INVENTOR. (7442455 .64/L BY 7 June 2, 1959 c. H. GAIL 4 7 2,888,960

BED SPRiNG MACHINE Filed Ham. 3, 1955 3 Sheets-Sheet 3 TOGELE ON 64 MASTER 5w -69 77 jfffl fffl HELICAL CUTTER ON IN VEN TOR. (664E155 64/4 ATTORNEY Unite States Patent BED SPRING MACHINE Application January 3, 1955, Serial No. 479,313 Claims. (Cl. 14092.8)

Calif., a corpora- This invention relates to a machine for producing bed springs of the type disclosed in Patent No. 2,663,038, issued December 22, 1953. The invention deals more particularly with novel means to control the operation of the machine components that form and feed helices to connect adjacent rows of spring coils, and cut and twist the ends of said helices.

An object of the present invention is to provide, in a machine that embodies means to hold two adjacent rows of spring coils in position to be connected, novel and improved means, started in operation by means moved to lock said holding means, for successively forming, feed ing, cutting and twisting the ends of helical connectors for the spring coils thus held.

Another object of the invention is to provide means to time the cycle of operation of a bed spring machine, to institute operation of such cycle timing means only after two adjacent rows of spring coils are properly held in position, utilize said timing means to form, feed, cut and twist the ends of helices that connect said rows of spring coils and provide means to obviate the operation of means controlled by said cycle timing means, in the event of failure of portions of the machine to function properly, while the cycle timing means completes its cycle of operation and returns to initial or starting position.

A further object of the invention is to providea machine, as indicated, that, optionally, may be manually operated, as when setting the machine in proper operating condition, or automatically operated in its normal manner.

The invention also has for its objects to provide such means that are positive in operation, convenient in use,

easily installed in a working position and easily disconnected therefrom, economical of manufacture, relatively simple, and of general superiority and serviceability.

The invention also comprises novel details of construction and novel combinations and arrangements of parts, which will more fully appear in the course of the following description. However, the drawings merely show and the following description merely describes, one e'm bodiment of the present invention, which is given by way of illustration or example only.

similar parts in the several views.

Fig. 1 is a front elevational view of a bed spring machine, the same, quite generally, showing some of the components that are controlled by the means of the present invention.

7 Fig. 2 is a cross-sectional view as taken on line 2-2 of Fig. 1.

Fig. 3 is an enlarged vertical sectional view as taken on line 3-3 of Fig. 1, the view being extended to show In the drawings, like reference characters designate Spring bars are firmly in position before helix feed is instituted.

upper and lower portions of the machine not shown in I Fig. l.

Fig. 4 is a wiringdiagram of the instrumentalities of 2,888,960 Patented June 2, 1959 For a clearer understanding of the means disclosed in Fig. 4, reference will first be made to Figs. 1, 2 and 3 as an example of a machine that constitutes the basis for the control means of Fig. 4. a The bed spring machine that is illustrated comprises, generally, a frame 10 which carries all of the hereinafter enumerated means; similar upper and lower helix-forming and -feeding units 11 and 12; a drive 13" for said units; similar upper and lower means 14 and 15 cooperating to engage rows of spring coils l6 therebetween to hold said coils in fixed position in side-by-side adjacent rows to receive helices 17 fed thereto by units 11 and 12; similar upper and lower means 18 and 19 for moving upper and lower portions, on one side, of the means 14 and 15; similar upper and lower means 20 and 21 for moving upper and lower portions on the other side; fixed upper and lower means 22 and 23 for guiding the manual positioning between them of rows of spring coils for subsequent movement by the means 18, 19, 20 and 21; means 24 responsive to an obstruction to the feed of the helices to stop operation of the units 11 and 12; and upper and lower front units 25 and 26 and upper and lower rear units 27 and 28 for cutting both ends of both helices and for forming said ends into closed loops.

The foregoing, disclosed in detail in said patent, may be varied in different ways and is here used to set a typical environment in which the present improvements are used. Except as follows, said means will not be detailed.

Drive 13 is connected to a suitable driver such as an electric motor 29, a clutch 30 being interposed in this driving connection to couple or uncouple shaft 31. A valve 32 controls supply of air to an air cylinder 33 connected to control said clutch. A solenoid 34, when energized, operates said valve to move the same to cause air flow to that end of cylinder 33 that moves the clutch to clutched position. When the solenoid is deenergized, a spring returns said valve to the position that declutches said clutch. This control of clutch 30 is shown in the diagram, Fig. 4, and is typical of air cylinders that operate the cutters of units 25, 26, 27 and 28 by meansfof solenoid 34a and valve 35, and operate the twisters of said units by means of solenoid 36 and valve 37. In Fig. 2, two of the cylinders that operate two of the four cutters are shown at 38 and two of the cylinders that operate the twisters are shown at 39.

Each of the means 14 and 15 comprises side-by-side longitudinal bars 40 and 41 that carry means 42 and 43 which cooperate, when the bars 40 and 41 are together as in Fig. 3, to hold two adjacent rows of coils 16 in position to receive and be connected by helices 17. Said bars 40 and 41 are locked in said position by toggle means 44 and 45, respectively. Thus, since there are two bars above and below, there are four toggle means, each of which must be straightened, as shown, to insure that the Each toggle means 44 and 45 comprises pivotally connected links 46 and 47, the former pivot-ally connected to bar 40 or 41, as the case may be, and the latter pivotally connected to an adjustable block 48 carried by the.ma-

chine frame. Link 46 is formed with an extension 49 and the same carries a bifurcated block 50 that is engaged by a lug 51 on a vertically extending rod 52. It will be clear that an upward shift of said rods, in the upper portion of the machine, will cause the toggles to break from the straightened position shown.

Since the arcuate movement of the link 47, when moving to a folded position, is substantially greater than the longitudinal movement of rod 52, means 53 is provided in a guide block 54 for said rod to ,rotatelug 51 ment of rod 53 is effected by means of an air cylinder 55 which also is used to depress rod 52, afterlugSl 3 has been brought into engagement with the bifurcations of block 50, and straighten the toggle links 46 and 47.

Each toggle means 44 and 45, as it straightens, closes a switch 56. Fig. 4 shows four such switches connected in seriesone for'each toggle means. Since switches 56 are normally open and are closed only when two adjacent rows of spring coils are in proper position to be connected by helices, closing of all four switches is necessary to enable the machine to carry out its cycle of operation.

, Ylt will be understood that the shafts 57 of the means 18 and 19 are driven by a suitable motor or the like .to move bars 40 and 41 to and from spring coil holding position. One of said shafts 57 is shown in Fig. 4 and is provided witha, cam lug or the like 58 for momentarily closing a switch 59.

A switch 60 is connected in series with switch 59, the same being normally closed, and is opened only when a bed spring is completed by the machine and said spring embodies a predetermined number of helical-connected rows of spring coils. In other words, the completed bed spring or any suitable counting mechanism driven from one of the shafts 57 opens switch 60.

, As seen in Figs. 1 and 2, the helices 17 pass through means 24, the same comprising troughs having displaceable lids or, covers. Should the feed of the helices be abnormally resisted, as when the ends of said helices cannot properly thread around the convolutions of the spring coils that are to be connected, buckling of the .helices results and the same displace the trough lids. This movement of the lids, when the same occurs, opens one or both of the normally-closed switches 61 connected in series with the toggle-operated switches 56 (Fig. 4). A second-pair of normally-closed switches 62 (Fig. 4) is so placed as to be opened by the end of each helix 17 after the same have effected connection of two rows of spring coils. These latter switches are connected in series with switches 56 and 61.

, Power is provided for the machine from a 110volt line 63 that is connected to a master switch 64 and which, through conductors 65 connecting said switch to a step-down transformer 66, provides low voltagepower inconductors 67 and 68. Said master switch is shown with four central terminals to which the switch blades are connected, four terminals at the right adaptedto be connectel by said blades with the aligned central term i nals and four terminals at the left also'adapted to be connected by said blades to the central terminals. Thus, master switch 64 actually comprises a gang of' four single-pole double-throw switches. The full-line position ofthe blades, as shown, connects the machine for normal ,or automatic operation. The dotted-line position conmeets the machine for manual or setting-up operation. The, machine, as contemplated herein, includes a cycle timer 69 which is shown in Fig. 4 as comprising a motor that drives a shaft 71, a set of individually-adjustable vearns 72, 73, 74, 75,76, 77 and 78 mounted on said shaft, a set of switches 79, 80, 81, 82, 83,84 and 85 controlled by the respective cams 72 to 78, and a solenoid 86. Ofthese switches, switch 80 is normally closed,

fswitch85 is a double-pole single-throw switch, and the others are normally open when the timer is at rest and before the institution of a cycle" of operation.

. The machine is provided with a green tell-tale light i 87 that is lit when the machine has completed its cycle "ofoperation, and a red tell-tale'light 88 that islit during the cycle of'op'eration.

The manner of electrical connection 'of the above elements will be described in connection with the following description of a cycle of operation:

he master s'wit ch'64' is thrown to automatic, the full-line position of Fig. 4. The machine is' then set into operation to cause the means 14 and 15 to bring two adjacent rows of spring coils 16 into position, as -1n F ig. 3; to be connected by upper and lower helices17.

i 2) that project slides 113'which control cutters 114.

Hence, shafts 57 rotate and, during the cycle of operation, make one complete revolution.

After the cam means 18 and 19 have brought the bars 40 and 41 and the cooperating means 42 and 43 thereon toward each other, the cam lug 58 on one of said shafts 57 momentarily closes switch 59. If normallyclosed switch 60 is closed, a low voltage electric circuit to energize solenoid 89 is closed from conductor 68, master switch blade 90, conductor 91, series switches 59 and 60, conductor 92, solenoid 89, conductor 93, to conductor 67. This energization of solenoid 89 moves a valve 94 to a position-the one shownthat directs pressure air to cylinders 55'to1project the upper rods 52 downwardly and the lower rods 52 upwardly and, thereby, straightentogglemeans 44 and 45 and lock the means 42 and 43 of bars 40 and 41 in spring coil-holding position. If all is normal, the toggle means, when straightening, will close the four toggle switches 56.

Since'switches'61 and 62 are normally closed, closing of toggle switches 56 closes a low voltage electric cir- =c uit to energize solenoid 86 from conductors 67, 93 and 95, solenoid '86, conductor 96, cam-closed switch 80, conductor 97, series'switches 56, 61 and 62, conductors 98, 99 and 91, switch blade'90 to conductor 68.

Although solenoid 86'is shown remote from switch 79, said switch is closed by said solenoid when the latter is energized. Closing of switch 79 closes a high voltage electric circuit through motor 70 from one side of the 110 volt line 63 to switch blade 100, switch connection 101, conductor 102, motor 70, conductor 103, switch 79, conductor 104, switch blade 105, to switch connections 106 and the other side of line 63. After rotation of shaft 71 is instituted by the motor circuit thus closed, said circuit is maintained by cam 72 holding switch 79 closed while switch is permitted to open by cam 73 to deenergize solenoid '86. Hence, regardless of any of the switches 56, 61, or 62 opening, the motor 70 will continue to operate until cam 72 permits switch 79 to open, the same beingat the end of one revolution of shaft 71. At that time, cam 73 will close switch 80 to readythe cycle timer for the next operation cycle.

Before the motor 70 started operation of-the cycle timer, the closed contact of switch held the circuit through theg'reen light 87 closed. This circuit is closed from conductors 67,93 and 107, lamp 87, conductors 108 and 109, switch 85, conductors 99 and 91, switch blade 90, to conductor 68. As soon as shaft 71 starts rotation, cam 78 opens thev green light circuit by shifting "switch 85 to engage the other terminal thereof and close the circuit through the red light. Thus, the light circuit includes conductor 110 instead of conductors 108 and 109 and red lamp 88 instead of green lamp 87. The red light circuit maintains until the cycle is completed, when switch 85'shifts back tothe green light circuit, as permitted by cam 78.

Now 'that'the cycle timer has been set into operation, the cams 74, 75, 76 and 77, in succession and according to the time-setting of their switch-controlling lobes, close the respective switches 81, 82, 83 and 84.

N Switch 81, when closed, energizes solenoid 34 to move valve '32 in position to direct air to cylinder 33 and couple motor- 29 with shaft 31, thus instituting operation of helix-forming and -feeding units 11 and 12. The low voltage electriccircuit that energizes solenoid 34 comprises conductors 67 and 111, said solenoid, conductor ;112 switch 81, and then through switches 56, 61 and 62, as before, to conductors 68. A similar circuit is w) made through solenoid 34a and switch 82 to move valve I 35 'Thus, iri proper sequence, as controlled by cams :74, 75, firstthe helix-units 11 and 12 and then the helix" cutters 25,26, 27 and 28 are operated, the former through cylinder 33 and the latter through.,-cylinder 38 Since the helices 17 now connect adjacent rows .of

75 coils 16, opening movement of the means 14 and :15 may be started. However, since the toggle means 44 and 45 are straight, they cannot be broken except by breaking the joints thereof between links 46 and 47. This is accomplished by raising upper rods '52 and lowering the lower rods (Fig. 3). The movement of these rods is effected by cylinders 55 under control of valve 94 which, then, must be moved so that air is directed to said cylinders in a manner to move said rods as stated. Energization of a solenoid 115, aligned with solenoid 89, by closing of switch 83 by cam 76, provides a low voltage electric circuit which includes conductors 67, 93 and 116, solenoid 115, conductors 117 and 118, switch 83, and, as before, switches '56, 61 and 62, conductors 98, 99 and 91, switch blade 90, and conductor 68.

While this latter circuit is breaking the toggle means, cam 77 may close switch 84 to close a low voltage circuit through solenoid 36 that controls valve 37 which, in turn, directs air to cylinders 39 (Fig. 2) so as to operate the twister heads that are parts of units 25, 26, 27 and 28. Since the toggle means 44 and 45 are in the process of being opened or broken at this time, the toggle switches 56 will be open. Therefore, the circuit established by closing of switch 84 includes a conductor 119 between switch 84 and switches 61 and 62. Thus the circuit for solenoid 36 varies from that of solenoids 34 and 34a by omitting switches 56. In other respects, the three circuits are alike.

It will be noted that valve 94 retains the position to which moved by solenoid 89 or 115. However, valves 32, 35 and 37 always seek the positions shown, as by suitable springs, except when moved by the solenoids to which connected. Therefore, the duration of energization of each said solenoid 34, 34a and 36, as controlled by the lobes of the respective cams 74, 75 and 77, determines the engaged period of clutch 30 and the time of operation of units 11 and 12, and the time periods necessary to operate the cutters and the twister heads.

As the bed spring builds up in size with successive rows of spring coils connected to rows already helically connected, it is desired to omit feed of the helices thereby separating a finished bed spring from the first row of the next spring being built up. Such omission is effected by not starting operation of units 11 and 12 and results from switch 60 being opened by either the finished bed spring or by a suitable device that is operated by a predetermined number of revolutions of one of the shafts 57. Since switch 60 is open, solenoid 89 remains deenergized and the mechanical components of the machine go through the cycle of operation that brings a new row of spring coils 16 in position to be connected by helices. However, since none of the devices 11, 12, 25, 26, 27 or 28 will operate due to non-operation of the cycle timer, said new .row of spring coils will remain unconnected.

If, once the operation of the cycle timer is instituted,

.one of the switches 61 or 62 is opened, the former, by a ;faulty feed and the latter by an overfeed, then said :timer will complete its full revolution of shaft 71 to end ;in starting position again. .84 will be in open circuit because the circuits thereof depend on all switches 61 and 62 being closed. Therefore,

However, switches 81 to :all of said devices will cease to function although the cycle timer 69 restores itself to starting position.

The present machine is also provided with means whereby the components thereof may be manually oper- .ated. This is accomplished through the medium of master switch 64 having its blades moved to the dotted position shown and through the medium of an index solenoid 120 and an air valve 121 controlled thereby. It will be noted that blade 185 of master switch 64, when moved to manual position, is out of circuit and takes motor switch '79 out of circuit. Hence the cycle timer 69 cannot operate. However, the switch blades 100 and 100a still connect the 110 volt line 63 to transformer 66 by means of conductors 65.

Since switches 81, 82, 83 and 84 cannot be closed,

because of inoperation of the cycle timer, the same are replaced in the circuits that energize the respective solenoids by switches 81a, 82a, 83a and 84a. These latter switches are normally open and, when closed, energize the solenoid to which connected in the same way that the switches 81 to 84 energize said solenoids.

All of the switches 81a to 84a are commonly connected to low voltage by a conductor 122. Switch 81a is connected to the conductor 112 in the circuit of which switch 81 and solenoid 34 are connected. Similarly, switch 82a is in circuit with solenoid 34a and across switch 82; switch 83a (a double-throw switch) is con-, nected to energize solenoids 89 or 115, selectively; and switch 84a is in circuit with solenoid 36 and across switch 84.

Also two (or more, if desired) manual switches 123 and 124 may be connected in parallel, as shown, and placed in a low voltage circuit with solenoid as follows: conductor 68, master switch blade 90, conductors 91 and 99, normally-closed contact of switch 85, conductor 109, either switch 123 or 124 (when manually closed), conductor 125, solenoid 120, and conductors 111 and 67.

Switches 123 and 124 are preferably placed at different or 'at opposite ends of the machine so as to be accessible where desired. The air valve 121 controlled, through solenoid 120, each time one of said switches is closed, controls mechanism for driving the machine. Release of the switches stops the machine, which, therefore, can be operated intermittently and as desired. During such intermittent drive of the machine, the switches 81a to 84a may be manually closed and released to effect a manuallycontrolled cycle of operation that enables servicing, adjusting, timing, etc. of the machine.

The foregoing contemplates that the helix cutters and the twisters be separately controlled mechanisms, the cutters being controlled through the medium of solenoid 34a and valve 35, and the twisters through the medium of solenoid 36 and valve 37. It will be evident that a separate control circuit for the twisters may be omitted if the twisters and cutters are mechanically connected so that they act in sequence upon closing of the operating circuits for the cutters. Under such conditions, the valve 37, solenoid 36 and cam 77 together with its switch 84, may be omitted and the control connections made through the medium of cam 75 and switch 82. In effect, the functions of the twister and cutter operators are combined in the diagram of Fig. 4.

Also, the machine will function satisfactorily if .the toggle means 45 were to be omitted and the toggles thereof replaced by simple levers or arms pivotally mounted on blocks 48 at the right of Fig. 3 and the ends of said arms pivotally connected to bars 41. In such case, the means 20 and 21, on the right, may be omitted also.

While the foregoing illustrates and describes what is now contemplated to be the best mode of carrying out the invention, the construction is, of course, subject to modification without departing from the spirit and scope of the invention. It is, therefore, not desired to restrict the invention to the particular form of construction illustrated and described, but to cover all modifications that may fall within the scope of the appended claims.

Having thus described the invention, what is claimed and desired to be secured by Letters Patent is:

1. In a control apparatus for use with a spring assembling machine having releasable holding means for holding two rows of spring coils together in position to be tied, helix forming and feeding means for threading a wire helix onto said coils, cutting means for cutting off said helix, and twisting means for twisting the ends of said helix, the combination comprising switch means adapted to be operated in response to full actuation of said holding means, a cycle timer having an operating motor, a motor control switch for energizing said motor, means responsive to operation of said switch means for operating said motor control switch, a cam operable by said.

motor and effective upon initial movement of said cam to'hold said motor control switch in operated position for a predetermined cycle, first, second, third and fourth cam means operable by said motor, first, second, third and fourth switch means operable sequentially by the corresponding cam means, first control means operable by said first switch means and adapted to actuate said helix forming and feeding means, second control means operable subsequently by said second switch means and adapted to actuate said cutting means, third control means operable subsequently by said third switch means and adapted to release said holding means, and fourth control means operable subsequently by said fourth switch means and effective to actuate said twisting means.

2. In a control apparatus for use with a spring assembling machine having releasable holding means for holding two rows of spring coils together in position to be tied, helix forming and feeding means for threading a wire helix onto said coils, cutting means for cutting off said helix, and twisting means for twisting the ends of said helix, the combination comprising switch means adapted to be operated in response to full actuation of said holding means, a cycle timer having an operating motor, means for energizing said motor in response to operation of said switch means, first, second, third and fourth cam means operable by said motor, first, second, third and fourth switch means operable sequentially by the corresponding cam means, first control means operable by said first switch means and adapted to actuate said helix forming and feeding means, second control means operable subsequently by said second switch means and adapted toactuate said cutting means, third control means operable subsequently by said third switch means and adapted to release said holding means, and fourth control means operable subsequently by said fourth switch means and adapted to actuate said twisting means.

3. :In a control apparatus for use with a spring assembling machine having releasable holding means for holding two .rows of spring coils in position to be tied together, tying means for feeding and cutting helical tie wires to said coils, and twisting means for twisting the ends of said wires, the combination comprising switch means adapted to be-operated in response to full actuation ofsaid holding means, a cycle timer having an operating motor, means for energizing said motor for a predeterminedcycle in response-tooperation of said switch-means, first, second and third cam means operable by said motor, first, second and third control switch means operable sequentially by the corresponding cam means, first control means operable by said first switch means and adapted to actuate said tying means, second control means operable subsequently by said second control switch means and adapted to release said holding means, and third control means operable subsequently by said third control switch means and adapted .to actuate said twisting means.

4. In a control apparatus for use with a spring assembling machine having releasable holding meansfor holding two rows .of spring coils in position to be tied to gether, and tying means for forming, feeding, cutting and twisting helical .tie wires to tie said coils together, the combination comprising switch means adapted to be operated in response to fullactuation of said holding means, a cycle timer having an operating motor, a motor con trol switch for energizing s'aid motor, means responsive to operation of said switch means for operating said motor control switch, a cam operable by said motor and effective .upon initial movement of said cam to hold said motor control switch in operated position for :a predetermined cycle, icam me'ans operable by said motor, control switch means operable by said cam means, con trol means .operable by said control switch means and adapted to actuate said tying means, additional cam means operable by said .motor, additional control switch means operable by said additional cam means, and additional control means operable by said additional control switch means and adapted to release said holding means.

5. In a control apparatus for use with a spring assembling machine having releasable holding means for holding two rows of spring coils in position to be tied together, and tying means for forming, feeding, cutting .and twisting helical tie wires .to tie said coils together, the combination comprising switch means adapted to be operated in response to full actuation of said holding means, a cycle timer having an operating motor, means for energizing said motor for-a predetermined cycle in response to operation .of said switch means, cam means operable by said motor, control switch means operable by said cam means, :control means operable by said control switch means and adapted to actuatesaid tying means, additional cam means operable by said motor, additional control switch means operable by said additional cam means, and additional control means operable by said additional control switch means and adapted ,to release said holding means.

References Cited in the file of this patent UNITED STATES PATENTS 2,625,963 'Bronstien Jan. 20, 1953 2,640,958 Davis June 2, 1953 2,663,038 Gail Dec. 22, 1953 

